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LED lamp provided with optical diffusion layer having increased thickness and method of manufacturing thereof

a technology of optical diffusion layer and led lamp, which is applied in the manufacture of electric discharge tube/lamp, luminescent screen, lighting and heating apparatus, etc. it can solve the problems of easy production of color unevenness, white light, and inability to manufacture white light, so as to reduce color unevenness and eliminate color unevenness , the size and shape precision of the phosphor resin portion is sufficiently high, and the effect of reducing color unevenness

Inactive Publication Date: 2009-04-07
SOVEREIGN PEAK VENTURES LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The solution effectively reduces color unevenness by scattering obliquely radiated light, maintaining high precision in phosphor resin formation and increasing manufacturing throughput while achieving luminous flux comparable to traditional illumination sources.

Problems solved by technology

An LED lamp of this type, however, easily produces color unevenness because the LED chip of each color has an excellent monochromatic peak.
That is to say, unless the light rays emitted from the respective LED chips are mixed together uniformly, color unevenness will be produced inevitably in the resultant white light.
However, the luminous flux of a single LED chip is too low.
As a result, unwanted color unevenness is produced.
However, the present inventors discovered that the color unevenness still persists in the prior art in the following situation.
However, even if one tries to form such a resin portion 113 with rounded corners by the printing technique, it is difficult to cut holes in such a shape through a printing stencil.
Thus, the holes cannot have the exactly intended shape.
As a result, the color unevenness could not be eliminated from the LED lamp as a whole.

Method used

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  • LED lamp provided with optical diffusion layer having increased thickness and method of manufacturing thereof
  • LED lamp provided with optical diffusion layer having increased thickness and method of manufacturing thereof
  • LED lamp provided with optical diffusion layer having increased thickness and method of manufacturing thereof

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Embodiment Construction

[0111]While looking for a good idea for minimizing the color unevenness to be produced by an LED lamp, it occurred to the present inventors that the color unevenness should be reduced significantly if the light radiated obliquely upward (in yellowish white) was scattered and mixed with the other light rays producing color white. However, if a method of making a structure that causes such scattering were too complicated, then the mass productivity of LED lamps would decline and the manufacturing cost thereof would rise. For that reason, the color unevenness is preferably minimized by using as simple a structure as possible. In view of this consideration, the present inventors discovered that the color unevenness could be reduced effectively by covering the phosphor resin portion with a light-transmissive resin portion in which a diffusing agent is dispersed as fine particles (i.e., an optical diffusion layer), thus acquiring the basic idea of the present invention.

[0112]An LED lamp a...

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Abstract

An LED lamp according to the present invention includes: at least one LED chip 12 that is mounted on a substrate 11; a phosphor resin portion 13 that covers the LED chip 12; a lens 22 to act on the outgoing light of the phosphor resin portion 13; and an optical diffusion layer (light-transmissive resin portion 20), which is arranged between the phosphor resin portion 13 and the lens 22 and in which particles to scatter the light are dispersed.

Description

RELATED APPLICATIONS[0001]This application is the U.S. National Phase under 35 U.S.C. § 371 of International Application No. PCT / JP2005 / 006959, filed on Apr. 8, 2005, which in turn claims the benefit of Japanese Application No. 2004-122550, filed on Apr. 19, 2004, the disclosures of which Applications are incorporated by reference herein.TECHNICAL FIELD[0002]The present invention relates to a method for fabricating an LED lamp and to an LED lamp and more particularly relates to a method for fabricating a white LED lamp that can be used as general illumination and to a white LED lamp.BACKGROUND ART[0003]A light emitting diode (which will be referred to herein as an “LED chip”) is a semiconductor device that can radiate an emission in a bright color with high efficiency even though its size is small. The emission of an LED chip has an excellent monochromatic peak. To produce white light from LED chips, a conventional LED lamp arranges red, green and blue LED chips close to each other ...

Claims

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Application Information

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Patent Type & Authority Patents(United States)
IPC IPC(8): H05B33/00F21Y101/02H01L33/32H01L33/50H01L33/54H01L33/56H01L33/60H01L33/62
CPCF21S6/003H01L33/50H01L33/56F21K9/00F21S6/00F21Y2101/02H01L2933/0091H01L2224/48091H01L2924/00014F21Y2105/001F21Y2105/10F21Y2115/10F21K9/64
Inventor YANO, TADASHITAKAHASHI, KIYOSHISHIMIZU, MASANORI
Owner SOVEREIGN PEAK VENTURES LLC
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